FUEL LEVEL CONTROLLER

LC300

Last Revision Date: March 9, 2016 For the most up-to-date information for this product and others, please

contact Simplex, Inc. at (800) 637-8603 or visit us on the web at http://www.simplexdirect.com.

Many of the illustrations and instructions in this manual refer to the standard configuration for this product. If you have requested

customizations, the drawings provided with your order take precedence; please refer to them for details specific to your order.

If you have any questions, please contact Simplex at 800-637-8603.

Table of Contents1 Warnings and Cautions ........................................................ 1

Safety information symbols 1Cautions 1

2 Nameplates and Placards ..................................................... 3

3 Unpacking ............................................................................. 5Included Components and Parts 5Primary Inspection 5

4 Description and Specification .............................................. 6Overview of Use 6Capabilities 6Safety 6

5 Installation ............................................................................ 8Installing Wiring 8Installing Cable Access 8Installing control power 8Installing Float Assemblies 8Installing Dry Contact Alarms (If ordered) 9Installing solenoid valves 9

6 Operating Instructions .......................................................10System Check 10Test Fill 10Sequence of Operations 10

7 Alarms and Warnings ..........................................................11Alarms 11Warnings 11

8 Maintenance/Troubleshooting ..........................................12Preventative Maintenance 12Troubleshooting 12

APPENDIx A — PRODUCT WARRANTY .................................................14

Table of FiguresFuel Level Controller ........................................................................................5Float Assembly ..................................................................................................5Controller dimensions ....................................................................................7Float Assembly Cable ......................................................................................8Troubleshooting Table ................................................................................. 13

Warnings and Cautions — 1

1 WARNINGS AND CAUTIONSThe following images indicate important safety information:

This General warning symbol points out important information that, if not followed, could endanger personal safety and/or property.This Explosion warning symbol points out poten-tial explosion hazards.

This Fire warning symbol points out potential fire hazards.

This Electrical warning symbol points out potential electrical shock hazards.

• Improper operation of this equipment such as neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate, and/or maintain this equipment.

• Potentially lethal voltages and amperages are present in these machines. Ensure all steps are taken to render the machine safe before attempting to work on the equipment.

• All hardware covered by this manual have dangerous elec-trical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., on the hardware, if applicable. Ensure all appropriate covers, guards, grounds, and barriers are in place before operating the equip-ment. If work must be done around an operating unit, stand on an insulated dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DAN-GEROUS ELECTRICAL SHOCK MAY RESULT.

• If trained personnel must stand on metal or concrete while installing, servicing, adjusting, or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 requires the frame of the equipment to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition or by static electricity. Never discon-nect the ground wire.

• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical current

Safety information

SymbolS

!!

CautionS

2 — Warnings and Cautions

(ampacity) to which they will be subjected.• Before installing or servicing this (and related) equipment,

make sure that all power voltage supplies are completely turned off at their source. Failure to do so will result in haz-ardous and possibly fatal electrical shock.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a noncon-ducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and seek immediate medical attention.

• Never wear jewelry when working on this equipment. Jewel-ry can conduct electricity resulting in electric shock or may get caught in moving components causing injury.

• Keep a fire extinguisher near the hardware at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insula-tion. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extin-guishers, please consult the local fire department.

• The illustrations in this manual are examples only and may differ from your unit.

!

Nameplates and Placards — 3

2 NAMEPLATES AND PLACARDS

4 — Nameplates and Placards

(800) 637-8603www.simplexdirect.com

Unpacking — 5

3 UNPACKINGThe following items

are included with your LC300 Fuel Level Con-troller. If any of the fol-lowing are not included, please contact your Sim-plex representative or call Simplex Direct, Inc., at 800-637-8603.

1. Fuel Level Controller2. Float Assembly(s)3. Manual4. Drawings package

Preventative visual inspection of the ship-ping crate and the fuel level controller is ad-vised. Never apply pow-er to a fuel level control-ler before performing this procedure. The fol-lowing four-point in-spection is recommend-ed before installation and as part of a 6-month maintenance schedule:

1. If the crate shows any signs of damage, examine the fuel lev-el controller in the corresponding areas for signs of initial problems.

2. Check the entire outside of the cabinet for any visual damage, which could cause internal electrical or mechanical problems due to reduced clearance.

3. Check electrical connections for tightness.4. Examine all accessible internal electrical components.

inCluded ComponentS

and partS

primary inSpeCtion

If any problems

are observed during

Primary Inspection,

call Simplex 24 hours a

day at 800-637-8603

Figure 1 Fuel Level Controller

Figure 2 Float Assembly

6 — Description and Specification

4 DESCRIPTION AND SPECIFICATION

The LC300 Fuel Level Controller provides intelligent con-trol and monitoring of fuel level for day tanks and other storage tanks.

The LC300 monitors the fuel level in a tank, keeping it at least half full in standard configurations. When the fuel level drops to to the Fill Start level, it calls for fuel. When the fuel level reaches Full level, it cancels the call for fuel and can optionally return fuel to the main storage tank, if needed.

With optional equipment, the fill controller can also shut down the generator if the fuel level reaches a critical low level and request a fill-up when the generator stops running.

The LC300 Fuel Level Controller is capable of monitoring and controlling round or rectangular tanks up to 100,000 gal-lons. The LC300 can optionally control two valves - one to ac-cept fuel, and another to return it to the main storage tank.

The controller’s main goal is to prevent overfilling of a tank and starving the generator’s fuel injectors. To that end, the con-troller has four float level switches to ensure the fuel level re-mains in normal operating range. If the fuel level rises past the full level to the high fuel level, the controller will register an er-ror.

The controller can also monitor a leak sensor. When a leak is detected, the controller ceases to ask for fuel until the error is cleared.

overview of uSe

CapabilitieS

Safety

Description and Specification — 7

Figure 3 Controller dimensions

11.0002.000

15.769

Level ControllerSRS Series

AUTO

OFF

CONTROL

FILL TEST

LEVELSTATUS

NOT IN

POWER

TANK

LOW

FILL

NORMAL

HIGH LEVEL

MANUAL

TANK

LOW LEVEL

FILL START

NORMALTANK FULL

HIGH LEVEL

AUTO

AVAILABLE

FULL

LEVEL

START

OPERATING

ALARM

FILLING

RANGE

ALARMOPERATING

RANGE

LC300 TANKLEVEL CONTROLLER

CUTOUT VALVEENERGIZED

PRESS TOSILENCE

HIGH LEVEL

10.171

10.090

24.075 25.128

0.500

15.180

8 — Installation

5 INSTALLATIONThe Fuel Level Controller should be mounted at the tank it

is monitoring, then wired to the power source, float assemblies, valves, and any other sensors or system integration connections.

The controller must be completely wired prior to applying power. Failure to follow the wiring information and guide may result in product damage and loss of warranty coverage. If re-quested, startup services can be provided by Simplex Onsite, Inc. or Simplex, Inc. to check field wiring prior to applying power as well as assuring proper operation.

To bring cabling into the fuel level controller, pull a hole into the cabinet at a location of your choosing and install a 3R-rated conduit connector for access.

To power your controller, connect a single-phase, 115VAC, 15A power source to TB-PS-9-10.

To install the float assembly, push the latch handles on the assembly down and slide the coupler off.

Apply an appropriate threadlocker to the threads on the cou-pler and screw it into the appropriate fitting.

Slide the assembly into the coupler and lift the latching arms until the assembly is locked into place.

Connect:

1. Common wire to TB-ASB-1

2. High Level Float wire to TB-ASB-2

3. Full Start Float wire to TB-ASB-3

4. Fill Start Level Float wire to TB-ASB-45. Low Level Float wire to TB-ASB-5

inStalling wiring

If there are any questions

about wiring the controller,

please contact

Simplex Inc. Simplex

Inc. is not responsible for damage

due to incorrect

wiring installation.

inStalling Cable aCCeSS

inStalling Control power

inStalling float

aSSemblieS

Figure 4 Float Assembly Cable

Installation — 9

To connect the controller to external alarms, connect TB-A-1-12 to your system as follows:

For Not in Auto alarm annunciation:

1. Normally Open to TB-A-12. Common to TB-A-23. Normally Closed to TB-A-3

For Leak alarm annunciation :

1. Normally Open to TB-A-42. Common to TB-A-53. Normally Closed to TB-A-6

For High Level alarm annunciation:

1. Normally Open to TB-A-72. Common to TB-A-83. Normally Closed to TB-A-9

For Low Level alarm annunciation:

1. Normally Open to TB-A-102. Common to TB-A-113. Normally Closed to TB-A-12

To connect valves, connect the following:

1. Solenoid 1 (fill valve): TB-SOL-1-32. Solenoid 2 (high cut-out valve): TB-PS-2 and TB-ASB-6

inStalling dry ContaCt

alarmS (if ordered)

inStalling Solenoid valveS

10 — Operating Instructions

6 OPERATING INSTRUCTIONS

Once installed, the Fuel Level Controller will not normal-ly require further interaction to maintain the fuel level in the tank. In the event that you do need to use the interface, read the following section closely to avoid errors that may interfere with proper operation.

Before filling the tank, check to see if any alarms (illuminated red lamps) or warnings (illuminated yellow lamps) are active.

The Test Fill button allows you to confirm that the panel is communicating with the fill pump correctly.

While the day tank’s fuel level is below the fill stop/tank full level, pressing the Test Fill button will cause the fuel level con-troller to send a call for fuel to the pump controller. Once the day tank’s fuel level increases to the fill stop/tank full level, the call for fuel signal is terminated.

If the filling operation is completed successfully, you can be assured the fuel level controller will operate correctly when needed.

The Fuel Level Controller allows automatic fuel level moni-toring and maintenance. As fuel is consumed and drops to the fill start level, the base tank controller generates a call for fuel. When the base tank reaches the tank full/fill stop level, the call for fuel signal is terminated.

If the fuel level reaches the High level, the controller will ac-tivate the lead return pump (if ordered) and trigger an alarm.

If the fuel drops below the fill start level to the low level, the controller will activate the lag fill pump (if ordered) and register an alarm.

SyStem CheCk

teSt fill

SequenCe of operationS

Alarms and Warnings — 11

7 ALARMS AND WARNINGSNormally equipped, the Fuel Level Controller registers three

alarms and three warnings.

All alarms are indicated via an audible horn and light on the panel. To silence the horn, push the “Silence Horn” button above the touch screen.

If there are any active alarms, contact the site supervisor im-mediately.

1. Low Fuel: The fuel level has fallen below the Fill Start level.2. High Fuel: The fuel level has risen above the Tank Full level.3. Not in Auto: The pump has been set to Hand or Off mode

The Fuel Level controller presents warnings for situations that are noteworthy but not necessarily in need of immediate at-tention. Active warnings are displayed only on the touch screen by yellow indicators.

1. Tank Full: The tank has reached the full level and cannot befilled any further.

2. Fill Start: The tank fuel has fallen to the low level and is send-ing a call for fuel to the fuel system.

3. Tank Filling: The pump is running and filling the tank.

alarmS

warningS

12 — Maintenance/Troubleshooting

8 MAINTENANCE/TROUBLESHOOTING

The Fuel Level Controller is designed to require minimal maintenance. On a yearly schedule, the unit should be fully opened and cleaned out. At this time, it would be a good idea to disconnect power and tighten all connections to ensure proper operation. This would also be a good time to tighten any mount-ing hardware.

To troubleshoot the Fuel Level Controller, a full set of draw-ings is required. Any electrical work should be performed by trained personnel. Simplex, Inc. is not liable for any damage or bodily harm. If additional help is required, contact Simplex or your local Simplex Onsite Branch for troubleshooting and onsite assistance.

preventative maintenanCe

trouble Shooting

Remove all power before servicing the

Fuel Level Controller.

Never operate or

service a fill controller that is not grounded.

Product Warranty - 13

SIMPLEX, Inc., warrants the industrial electrical control, test and accessory equipment and parts and accessories thereof to be the kind and quality described in SIMPLEX’s specifications and to be free from defects in material or workmanship under normal service, its obligations under this warranty being limited to repairing or replacing, at its option, any part or parts which shall, within twelve (12) months from date of shipment from its factory, as indicated by serial date code on the nameplate or sales records, be returned to SIMPLEX or an authorized SIMPLEX repair station, with transportation costs prepaid, and which its examination shall disclose to its satisfaction to have been thus defective.The provisions of this warranty shall not apply to any equipment, part or accessory which

(a) has been improperly specified by buyer;

(b) has been improperly stored or handled prior to placing in service;

(c) has been improperly mounted or connected;

(d) has not been operated within specifications stated on its nameplate, label orplacard;

(e) has not been properly maintained;

(f) parts supplied by buyer for inclusion in finished equipment are not covered bythis warranty;

(g) components or assemblies specified by buyer with no substitution permissiblethat are not normally used by SIMPLEX.

SIMPLEX reserves the right to reject warranty claims of any kind against assembled equipment, parts or material for which SIMPLEX has not received payment in full. Should buyer, at his own risk, elect to replace defective equipment or parts in the field rather than return equipment to SIMPLEX’s factory or authorized repair station, SIM-PLEX will supply and invoice parts at normal prices upon receipt of buyer’s bona-fide purchase order. Defective equipment or parts returned for in-warranty crediting in ex-change for replacement parts must be returned within 45 days from date of shipment of replacement in order to qualify for warranty consideration. Defective equipment or parts returned after 45 days may be subject to a restocking charge of 20% or a mini-mum charge of $50.00, whichever is greater.This warranty is in lieu of all other warranties, express or implied, and all other obliga-tions or liabilities on the part of SIMPLEX, and SIMPLEX neither assumes nor autho-rizes any other person to assume for it any other liability in connection with any such electrical control, test or accessory equipment or accessories or parts.

APPENDIx A — PRODUCT WARRANTY

WE WELCOME YOUR FEEDBACK!

Simplex designs and manufactures Load Banks and Fuel Supply systems for power generation and liquid automation. Simplex is certified to ISO 9001:2015.

Used world-wide for mission critical environments in manufacturing, technology, transportation, hospitals,

schools, public utilities and the U.S. military, Simplex products provide solutions meeting exact

requirements, from the simplest testing and proving equipment for backup generators to custom-designed

and engineered mission-critical fuel systems. At Simplex, we are experts at building products that meet

our customers’ exact requirements. For a complete listing of Simplex products visit

www.simplexdirect.com.

Simplex welcomes your questions, comments, suggestions, compliments, and complaints as a way to

continuously improve our service to you. Please call us at 800-637-8603 (24 hours a day)

or visit www.simplexdirect.com.

Simplex, Inc.5300 Rising Moon Road

Spring ield, IL 62711-6228

www.simplexdirect.com(800) 637-8603